Unitary front face frame for a refrigerator cabinet

ABSTRACT

A refrigerator includes cabinet shell including a pair of laterally spaced, upright side walls and a top wall, each of which includes a respective forward portion. A face frame, integrally formed from a single, bent material sheet, is mounted to the forward portion of each of the opposing side and top walls. The face frame includes top, bottom and opposing side frame members, along with a mullion member that extends between either the top and bottom frame members or the opposing side frame members, depending upon desired refrigerator configuration. The mullion member establishes first and second openings that lead into first and second refrigerated compartments or the refrigerator.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention pertains to the art of refrigerators and, more particularly, to a unitary face frame for a refrigerator cabinet.

2. Discussion of the Prior Art

In constructing an appliance cabinet, particularly a refrigerator cabinet, it is highly desirable to simplify the overall assembly of the cabinet to reduce manufacturing costs, yet it is imperative that the cabinet be structurally sound in order to counteract loads exerted thereon during use of the appliance. Mainly due to cost efficiencies and flexibility in workmanship, it has been commonplace to utilize sheet metal in the forming of most refrigerator cabinets in the market today. Since sheet metal is relatively thin and rather high loads are often placed on the cabinet, particularly by the opening and closing of a weighted down refrigerator door, a fair amount of effort has been applied in this art to provide reinforcement for such a refrigerator cabinet. Of course, an additional concern is the ease of assembly of the cabinet as a whole.

With this in mind, it has heretofore been proposed to form the sides and top of a refrigerator cabinet shell out of a single piece of bent sheet metal and then attach rear and bottom walls. Thereafter, the shell is structurally reinforced in an attempt to avoid deformation during use. Such known reinforcing arrangements generally take the form of either providing multiple, individually secured reinforcement members or individual members formed into a reinforcing frame which is then positioned at a front opening of the cabinet shell. At least the sides of the shell are attached to the frame to integrate the overall assembly. To perform this assembly operation, either various holes are provided in both the cabinet shell and the reinforcement members which must be aligned to receive mechanical fasteners or systematic welding operations are performed. In either case, these connections are designed to perform the sole function of interconnecting the shell to the reinforcement structure.

Constructing and mounting the reinforcing frame has proven to be a time consuming and costly manufacturing step. Forming individual frame members, joining the frame members to form an overall frame, and mounting the frame to the cabinet shell add a considerable amount of time to the manufacturing process. Likewise, forming the frame members and then fastening the frame members to the cabinet individually is also a labor intensive process.

Based on the above, there exists a need for a simplified reinforcing frame for a refrigerator cabinet. More specifically, there exists a need for a unitary face frame that is integrally formed from a single sheet of material and then fastened to an outer cabinet shell of a refrigerator.

SUMMARY OF THE INVENTION

The present invention is directed to a unitary face frame for a refrigerator. The refrigerator includes an outer cabinet shell having a pair of laterally spaced, upright side walls and a top wall, each of which includes a respective forward portion. First and second liners are arranged adjacent one another in the cabinet shell and define corresponding first and second refrigerated compartments.

In accordance with the invention, the face frame is integrally formed from a single material sheet and then mounted to the outer cabinet shell at the forward portion of each of the opposing side and top walls. The face frame includes top, bottom and opposing side frame members, along with a mullion member that extends between either the top and bottom frame members or the opposing side frame members, depending upon desired refrigerator configuration. The mullion member establishes first and second openings that lead into the first and second refrigerated compartments respectively.

Additional objects, features and advantages of the present invention will become more readily apparent from the following detailed description of a preferred embodiment when taken in conjunction with the drawings wherein like reference numerals refer to corresponding parts in the several views.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an upper right perspective view of a built-in refrigerator incorporating a unitary face frame constructed in accordance with the present invention;

FIG. 2 is an exploded view of the built-in refrigerator of FIG. 1 illustrating the unitary face frame;

FIG. 3 is an elevational view of the unitary face frame shown prior to a final forming process; and

FIG. 4 is an upper right perspective rear view of the unitary face frame of FIG. 3 following the final forming process.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

With initial reference to FIG. 1, a refrigerator constructed in accordance with the present invention is generally indicated at 2. Refrigerator 2 is shown to include a freezer door 6 having an associated handle 7 and a fresh food door 10 having an associated handle 11. In the embodiment shown, refrigerator 2 is of the recessed type such that, essentially, only freezer and fresh food doors 6 and 10 project forward of a wall 15. The remainder of refrigerator 2 is recessed within wall 15 in a manner similar to a plurality of surrounding cabinets generally indicated at 18-23. Refrigerator 2 also includes a plurality of peripheral trim pieces 28-30. In accordance with the most preferred embodiment of the invention, trim pieces 28-30 are formed of aluminum. However, other materials, such as plastic, could also be utilized. Finally, it should be noted that refrigerator 2 is preferably designed with main components of a refrigeration system positioned behind an access panel 32 arranged directly above trim piece 29 as clearly shown in this figure.

Although refrigerator 2 can take various forms, FIG. 2 represents, in exploded view form, the main cabinet components of a side-by-side model for refrigerator 2. As illustrated, refrigerator 2 includes a front frame 40 which, as will be detailed more fully below, is formed from a single sheet of material. Refrigerator 2 also includes a freezer compartment box 55 defined by interconnected side, bottom, top and back panels 57-61. In a similar fashion, a fresh food compartment box 65 is formed from side, bottom, top and back panels 67-71. As freezer compartment box 55 and fresh food compartment box 65 are preferably formed as separate units, they are integrated into an overall refrigerator cabinet assembly by front frame 40 and an outer shell as defined by side walls 80 and 81, a back wall 82 which is preferably defined by four separate panels 82 a-82 d, a bottom wall 83, a top cover member 84 and a front cover member 85. As will be detailed more fully below, front frame 40 is adapted to be attached to forward portions (not separately labeled) of each side wall 80, 81 such that, front frame 40, freezer compartment box 55, fresh food compartment box 65, side walls 80 and 81, back wall 82, bottom wall 83, top cover member 84 and front cover member 85 are all integrated together. Also provided about openings (not separately labeled) defined by front frame 40 are associated peripheral breaker elements 90 and 91 that snap-fittingly engage with front frame 40, freezer compartment box 55 and fresh food compartment box 65 to define corresponding freezer and fresh food compartments.

For the sake of simplicity, the various components of a conventional refrigeration circuit have not been shown. However, with this configuration of refrigerator 2, the various compressor, condenser, evaporator and the like components are preferably supported upon top panel 60 of freezer compartment box 55, as well as top cover member 84. In accordance with the most preferred embodiment of the invention, the evaporator is supported above freezer compartment box 55 while the compressor and condenser are located above fresh food compartment box 65, with each of these components being accessible upon removing access panel 32.

In accordance with the invention, front frame 40 includes top, bottom and opposing side frame members 110-113 along with a mullion member 117 that collectively define first and second openings 128 and 129. In the embodiment shown, opening 128 corresponds to freezer compartment box 55 and opening 129 corresponds to fresh food compartment box 65. Important in connection with the present invention, as best shown in FIG. 3, front frame 40 is integrally formed from a single sheet of material. Preferably, front frame 40 is formed by a stamping process such that openings 128 and 129 are stamped out of a single sheet of material such as, for example, aluminum.

In further accordance with the invention, in addition to establishing openings 128 and 129, the stamping process creates a plurality of outer edge portions 140-143 that correspond to top, bottom and opposing side frame members 110-113 respectively. Outer edge portions 140-143 are provided with a plurality of openings, one of which is indicated at 144, which, as will be discussed more fully below, are employed when connecting front frame 40 to the remainder of refrigerator 2. In addition to outer edge portions 140-143, front frame 40 also includes first and second plurality of inner edge portions 145-148 and 153-156. Inner edge portions 145-148 and 153-156 extend about and define openings 128 and 129 respectively.

Following the stamping process, front frame 40 undergoes a forming process during which outer edge portions 140-143 and first and second pluralities of inner edge portions 145-148 and 153-156 are folded or bent so as to define an outer peripheral U-shaped channel 161, as well as a U-shaped mullion channel 164, both of which open rearwardly as represented in FIG. 4. Outer peripheral channel 161 and mullion channel 164 are open at rear portions thereof so as to receive outer edge portions of freezer compartment box 55 and fresh food compartment box 65, as well as peripheral breaker elements 90 and 91 respectively.

In accordance with the most preferred form of the invention, peripheral frame 40 is provided with a plurality of corner or stiffening brackets 184-187 that are respectively arranged at an intersection (not separately labeled) of top and bottom frame members 110 and 111 with opposing side frame members 112 and 113. Each stiffening bracket 184-187 is generally L-shaped having first and second leg portions, indicated at 190 and 191 for bracket 184, which extend onto top frame member 110 and side frame member 113 respectively. Of course, the remaining stiffening brackets 185-187 include corresponding leg portions that extend onto top or bottom frame members 110, 111, as well as a respective side frame member 112, 113. In any case, stiffening brackets 184-187 are preferably fixedly mounted to front frame 40 through respective double-sided adhesive pads 195-198. Once in place, stiffening brackets 184-187 provide additional stiffening to front frame 40 so as to minimize racking forces which may occur during shipment.

Based on the above, it should be readily apparent that front frame 40, constructed in accordance with the present invention, provides for a simple, cost effective method of manufacture that removes many previously required steps to join top, bottom, opposing side frames and mullion members. By removing unnecessary steps in a manufacturing process, the present invention reduces costs and complexity associated with the construction of refrigerator 2 thereby providing the manufacturer with a competitive advantage.

Although described with reference to a preferred embodiment of the invention, it should be readily understood that various changes and/or modifications can be made to the invention without departing from the spirit thereof. For instance, while shown in connection with a built-in refrigerator, front frame 40 could also be employed in other side-by-side models, as well as top mount, bottom mount and French door style refrigerators. In general, the invention is only intended to be limited by the scope of the following claims. 

1. A refrigerator comprising: an outer cabinet shell including a pair of laterally spaced, upright side walls and a top wall, each of said side and top walls including a respective forward portion; a first liner defining a first refrigerated compartment arranged within the outer cabinet shell; a second liner defining a second refrigerated compartment arranged adjacent the first liner in the outer cabinet shell; and a face frame integrally formed from a single material sheet mounted to the outer cabinet shell at the forward portion of each of the opposing side and top walls, said face frame including top, bottom and opposing side frame members, along with a mullion member extending between one of the top and bottom frame members and the opposing side frame members, said mullion member establishing first and second openings leading into the first and second refrigerated compartments respectively.
 2. The refrigerator according to claim 1, wherein a plurality of the top, bottom and opposing side frame members are U-shaped in cross-section having respective opposing side portions that define a peripheral channel.
 3. The refrigerator according to claim 2, wherein the peripheral channel includes an open rear portion.
 4. The refrigerator according to claim 2, wherein the mullion member is U-shaped in cross-section having first and second opposing side portions that define a mullion channel.
 5. The refrigerator according to claim 3, wherein each of the first and second liners includes a pair of laterally spaced, upright side walls, a bottom wall and a top wall, each of said side bottom and top walls includes a respective forward portion that projects into the peripheral and the mullion channel.
 6. The refrigerator according to claim 5, wherein the refrigerator is constituted by a side-by-side refrigerator.
 7. The refrigerator according to claim 1, further comprising: a plurality of stiffening brackets, said top and bottom frame members meet the opposing side frame members to establish a plurality of corners, each of said plurality of corners being provided with a corresponding one of the plurality of stiffening brackets.
 8. The refrigerator according to claim 7, wherein each of the plurality of stiffening brackets is L-shaped.
 9. The refrigerator according to claim 7, wherein each said stiffening bracket is affixed to a respective one of the plurality of corners with a double sided adhesive pad.
 10. The refrigerator according to claim 2, wherein the face frame is stamped from a single sheet of metal with the top, bottom and opposing side frame members being bent to establish the peripheral channel.
 11. A method of assembling a refrigerator comprising: forming an outer cabinet shell having a pair of laterally spaced, upright side walls and a top wall, each of said side and top walls including a respective forward portion; positioning a first liner in the outer cabinet shell to establish a first refrigerated compartment; arranging a second liner in the outer cabinet shell adjacent the first liner to establish a second refrigerated compartment; and mounting a face frame, which is integrally formed from a single sheet of material to establish top, bottom and opposing side frame members, along with a mullion member extending between one of the top and bottom frame members and the opposing side frame members, to the outer cabinet shell at the forward portion of each of the opposing side and top walls, with said mullion member establishing first and second openings leading into the first and second refrigerated compartments respectively.
 12. The method of claim 11, further comprising: forming the sheet to create a U-shaped peripheral channel open at a rear portion thereof.
 13. The method of claim 12, further comprising: forming the sheet to create a U-shaped mullion channel open at a rear portion thereof.
 14. The method of claim 13, further comprising: arranging forward portions of the first and second liners in the peripheral channel and the mullion channel.
 15. The method of claim 13, further comprising: stamping the sheet from a single piece of metal.
 16. The method of claim 15, further comprising: bending the stamped sheet to form the peripheral channel and the mullion channel.
 17. The method of claim 12, further comprising: attaching stiffening brackets to the face frame, each of said stiffening brackets being positioned in the peripheral channel at a corner portion of the face frame.
 18. The method of claim 17, wherein each of the stiffening brackets are attached to the face frame with a double sided adhesive pad. 